Solar modular power with parallel AC and DC wiring

ABSTRACT

Modular solar systems comprise one or more module units that are connectable into a system/assembly for convenient installation on a roof or other surface that receives solar insolation. The modules are adapted for electrical, and preferably also mechanical, connection into a module assembly, with the number of modules and types of modules selected to handle the required loads. Each module is adapted and designed to handle the entire power of the assembly and to provide or receive control signals for cooperative performance between all the modules and for monitoring and communication regarding the assembly performance and condition.

This application is a continuation application of U.S. patentapplication Ser. No. 14/951,184, filed Nov. 24, 2015, the entiredisclosures of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention relates to modular solar systems that comprise one or moremodule units that are connectable into a system/assembly for convenientinstallation on a roof or other surface that receives solar insolation.The modules are adapted for electrical, and preferably also mechanical,connection into a module assembly, with the number of modules and typesof modules selected to handle the required loads. Each module is adaptedand designed to handle the entire power of the assembly and to provideor receive control signals for cooperative performance between all themodules and for monitoring and communication regarding the assemblyperformance and condition.

2. Related Art

For AC power systems (and all power systems where there is a load and asupply), the generation (supply power) and demand (load) must be equal.In other words, the Utility Supply must equal the Customer Load. Ifthere is ever a power outage, the re-connection of the circuits afterthe fault is cleared must be done carefully to assure that the loads areconnected in a phased or staged fashion. This assures that the requiredbalance is maintained while restoring power.

AC distribution systems are designed in such a way to allow this. Thereare distribution systems (with protection in the form of fuses andcircuit breakers) with switches to allow each part of the system to beisolated and controlled.

On both sides (supply and demand) of a conventional Utility Grid,therefore, the system is designed in sections or blocks of power toallow for this distribution and equalization. These divisions areisolated by circuit breakers, load centers, distribution panels,transformers and utility substations. This is because the power needs tobe carefully distributed from available generation systems that are inturn delivered to quantified loads that are supplied over wiring anddistribution circuiting sized to handle the specific power for eachcircuit.

Solar-powered autonomous devices have been designed for emergency use(for example, during power outage in a hurricane or other catastrophe),or for other non-grid tied applications, wherein “autonomous” hereinmeans the device is designed for, and relies solely on,solar-panel-charging of batteries or other energy-storage device,without a grid tie. Such conventional autonomous devices do not includethe balance of supply and demand that is included in certain embodimentsof the invention, and are not modularly-expandable, by connectingmultiple modules, as are certain embodiments of the invention. Suchconventional autonomous devices are built in a specific system, or“emergency box”, size, and cannot be expanded beyond that single sizeand power-producing capability. So, such conventional autonomous devicescannot be expanded to serve a larger load than the single “box” size isdesigned for. The only choice for serving larger loads with suchconventional autonomous systems is to buy a bigger system, that is, abigger, single “emergency box” with higher load-serving capacity.

SUMMARY OF THE INVENTION

The invention comprises a solar-powered module, and assemblies ofsolar-power modules, wherein the modularity allows easy transport andinstallation on a building roof or other surface where solar insolationoccurs. The modules are each adapted for electrical, and preferably alsomechanical, connection into a module assembly, wherein additionalmodules are added, either in the form of subordinate modules, primarymodules or main modules, to handle the required loads and to providecontrol of each of the modules, for example, to control how the solarpanels charge the energy-storage devices of each and all the modules viaa DC system, to control AC waveform of the inverter of each module, andto load-shed according to predetermined outlet/load priorities. Eachmodule is adapted and designed to handle the entire power rating/load ofthe assembly and to provide or receive control signals for cooperativeperformance between all the modules and for monitoring and communicationregarding the assembly performance and condition.

Each module in the preferred system is designed with a higher powerrating than what would normally be required for a single module, so thatfuture applications/uses may be served even when the total served loadchanges. Each individual module is therefore “ready” to accept thesehigher loads, if and when the individual modules is once placed in alarger system, that is, placed in an assembly of connected modules.Thus, while, in certain embodiments, some or all the modules areoperable and effective in single-module applications, the preferredmodules are “pre-sized” or “pre-adapted” to handle combined loads ofseveral modules connected together. In other words, each preferredmodule is sized to accommodate the loads of multiple modules and willact as a sub-panel within the assembly of modules, but the preferredmodules are electrically, and preferably mechanically, connectable andoperable, without requiring any conventional AC system service panel orsub-panel to be added to the assembly of modules, and without requiringthe services of an electrician.

Many objects of certain embodiments of the invention will becomeapparent from the following description, to solve needs forconveniently-packaged and shipped modules of uniform dimensions,convenient and clear electrical and mechanical connectability,convenient and clear status and performance monitoring and reporting,and/or effective grid-tie options with AC waveform control.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a single module.

FIG. 2 is a perspective view of another embodiment of the invention, anarray of several of the modules of FIG. 1 connected together.

FIG. 3a is an enlarged cross-section view, along the line 3 a-3 a inFIG. 2, of one embodiment of a connection between two adjacent modules.

FIG. 3b is an enlarged cross-section view, viewed along 3 b-3 b in FIG.4b , of one embodiment of a side edge of a module that is not adjacentto another module, with a channel cover that is slid onto that side edgeto cover and protect said side edge and its electrical elements.

FIG. 4a is a perspective view of an open module, according to theembodiment of FIG. 1, showing the airflow thru the enclosure.

FIG. 4b is a top view of six modules connected into an assembly,schematically showing cool air flowing into the lower ends of preferablyall the modules, and relatively hot air existing the upper ends ofpreferably all the modules, so that hot interior air from each moduledoes not travel through any other module before exiting to theenvironment of the assembly.

FIG. 5a shows the interior of the module of FIG. 1 with all of thepreferred components shown.

FIG. 5b is a cross section of the module, along the line 5 b-5 b in FIG.5a , showing the batteries, inverter and insulation.

FIGS. 6a-c are diagrams that show three different array configurationsto illustrate certain ways various modules can be connected together.

FIG. 7a is a schematic diagram of several modules connected togetherwith DC power as the main combining feeder circuit.

FIG. 7b is a schematic diagram of several modules connected togetherwith AC power as the main feeder circuit.

FIG. 8a illustrates how one embodiment of a small SMPS is connected tothe utility power grid.

FIG. 8b shows how one embodiment of a SMPS is connected to a sub-panelfor power distribution.

FIG. 9 is a wiring diagram of one embodiment of an individual module.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

Main System Components:

Certain embodiments of the invented Solar Modular Power System (SMPS)are for meeting the needs of an individual home, apartment building,individual business building, or other individual building, tosupplement, or supply entirely, said home's or building's energy needs.While the SMPS is of a scale and structure that is efficiently shipped,installed, and operated on a single home or building, the SMPS isspecially adapted to have features similar to those of a much largerpower system, that is, of a AC Utility Power Grid/System. Morespecifically, said features comprise that the system is divided intoindividual modules that can be controlled and balanced with each other,the solar supply power, and the loads they are serving.

The SMPS comprises, consists essentially of, or consists of, at leastone module, and preferably multiple of said modules, that can eachoperate and function independently. The module is a complete solarpowered power supply with energy storage that is completelyself-contained. The output of the module is AC power (via an electricalAC receptacle). Even in an individual module, the supply and demand mustbe managed and controlled.

The preferred system comprises, consists essentially of, or consists of,multiple modules connected together to increase the overall power of thesystem in order to serve larger loads. A single module may be onlycapable of serving a 10-amp, 120 VAC load. However, multiple moduleswhen connected together would be capable of serving much larger loads(up to 60 amps at 240 volts).

The Inventor has determined that multiple solar power supplies cannot bejust “simply connected” together, and so connection of multiple of theSMPS modules is specially designed and structured to include featuresthat are not included in conventional “solar in a box”, “plug and playsolar panels”, or “emergency solar box generators”. The inventor hasdetermined that each sub-system (module) of the SMPS must be integratedthrough a distribution system that: 1) Assures that each powergenerating system is balanced with the energy storage system(s), and theelectrical loads within the module; 2) Has circuit protection to protectagainst and isolate faults; and 3) Actively manages the power betweenthe modules (system balancing).

The approach taken to assure that this is done properly is to designeach module with the interfacing bus bar or wiring, for electricallyconnecting the multiple modules, being sized to accommodate the fullload of the combined system (once multiple modules are connectedtogether). The circuit protection, monitoring and control are alsodesigned to allow the balancing of the system, along with isolatingfaults in the system to allow the system to continue to operate whenthere is a failure in one of the system components. For example, if onebattery bank is failing, the system isolates this bank from the rest ofthe system in order to allow the remaining battery banks to operatewithout having the bad bank bringing down the entire system (potentiallylowering the voltage to a point that the loads can no longer be served).

The main module, or “primary” module, contains all of the system power,monitoring and control features for a complete and operational system.Additional subordinate modules can be connected to the primary module inorder to increase the overall power of the system. Each system has aspecific maximum power rating that corresponds to the total connectedpower rating of the combined system. In other words, if the largest loadto be expected from the system after all modules are connected togetherwill be 2 kW, then the primary and subordinate modules must have thissame rating. This assures that, once all of the modules are connectedtogether, the combined load over the bus bar and/or interconnectionwiring is large enough to handle this maximum load. The monitoring andcontrol system prevents the interconnection of modules with incompatibleratings.

Each module has a module rating and a system rating. The module ratingis what that single individual module is capable of producing (solarpower) and storing. The module has an energy rating (stating the totalstorage capacity), and a system rating that describes the maximum systemsize it can be integrated into. For a single module, the energy ratingmay be 1 kWh (storage capacity) with a power rating of 500 watts, and asystem rating of 2 kW. So, a total system consisting of four (4) 500 Wmodules with a system power rating of 2 kW would have a total energycapacity of 4 kWh (4 modules at 1 kWh each).

The two main forms of electrical power being monitored and controlled inthe system are AC power and DC power. Each individual module has both ofthese systems (AC and DC), which are isolated and separated from eachother within the module enclosure. See FIGS.

The modules are electrically connected by means of interconnection busbars (which preferably also mechanically connect the modules) and/orwiring, which allow the sharing of power between the modules. While busbars are preferred in certain embodiments, wiring by means ofelectrically-conductive wire or cable may be the interconnection means,or may supplement a bus bar interconnection means. Both DC and ACelectrical connection is shared over the bus bar or wiringinterconnection. In addition to AC and DC interconnection, themonitoring or network interconnected is also done by means of saidinterconnection bus bars or wiring. See FIG. 1, notes 7, 8, 9. Each ofthese systems (AC, DC, and data) are kept separated and isolated fromeach other over the bus bar and/or wiring interconnection.

The primary module (PM) can be viewed as an electrical load center ormain service panel that serves the load(s). All of the systemsubordinate modules (SM) feed into the PM in order to supply thecombined power required for the system. Thus, the load(s) served via thePM are supported by the power capacity of the total system. For example,4 modules at 500 watts each connected together would be able to serve 2kW of load.

The PM has circuit protection (fuses and/or circuit breakers) as well ascontrols to allow the isolation and control of each of theinterconnected SMs. Both supply and load power, within each module andalso within the system (that is, the combined system of PM and SMs), areable to be controlled, balanced and modified (if required—load sheddingor isolating faults) by the control system (or “controller”) of the PM.

For embodiments that require more power than a single PM with multipleSMs can provide, then 2 or more PMs can be connected to serve theselarger loads. If multiple, connected PMs are not enough, certainembodiments are designed to allow the integration of 2 SMPS systems.This is accomplished by adding a “Main” module that is rated higher thanthe PMs. So, for example, if the system is maxed out with (4) 2 kW PMs(for a total of 8 kW) and more power is needed, a Main module (M) thatis rated for 20 kW could be added to the system. For example, each of 4PMs would be connected to the M, and additional PMs (with attached SMs)could then be added to the entire assembly in order to achieve thehigher capacity. The M would be the only component that would need tohave the highest rating, since each system would be feeding into M, andwould only be exposed to the lower rating. Module M, along with itsoutput receptacle, would be rated for the highest capacity as required.

The inventor has determined that there are 3 requirements in order tocombine multiple modules according to preferred embodiments of theinvention:

1. Because the total SMPS (or “total system”) power delivered (and thepower produced from the solar) is higher for multiple modules, eachindividual module must be capable of supporting the total system power.So, if a single module, only capable of producing 500 watts by itself,is placed into a system that is capable of producing 2 kW, theindividual module must be able to handle the higher load of 2 kW. Anyshared components must be rated for the total or shared power ratingsonce they are connected together. So, for example, if the system issharing AC power, then each inverter must be rated for the paralleloperation with the other inverters in the system at the total deliveredpower rate. The electrical conductors (bus bar and/or wire) must besized to accommodate the total system load (not just the load of onemodule).

2. In order to benefit from the total system power of the combinedmodules, each module must be connected to the other modules in thesystem. This connection allows for the sharing of stored energy (higherstorage capacity compared to a single module). It also increases theavailable instantaneous power—the number of amps that can be deliveredin real time. This provides a higher inrush current for loads thatrequire higher amperage than a single module can deliver.

3. The DC power must be kept separate from the AC power. Since everymodule has both AC and DC “on board”, the sharing of power between themodules must also be kept separate (AC and DC must be isolated anddelivered to adjacent modules in separate wires or bussing).

Structural changes in the modules that are required in certainembodiments so that each module is adapted and designed to handle theentire power rating/load of the assembly, may include one or more, andtypically all, of the following:

1. In order to interconnect multiple modules, the bus bar or wiring thatconnects multiple modules must be sized large enough to handle thecombined loads served by the total system (with multiple modulesconnected together). This bus bar is preferred for the desiredmodularity, but, in certain embodiments wherein only one module will beused, it is not required.2. With multiple modules connected together, paralleling inverters arerequired so that the modules can share the combined power output (andthus increasing the total combined power output of the system). Or,alternatively but less preferably, one of the inverters in the systemmust be sized large enough to handle the total combined system load.3. With multiple modules connected together, there must be circuitprotection (circuit breakers) for safety and to isolate faults withineach module, and to separate these faults from the interconnectedmodules. The circuit breakers serve the purpose of power distribution toother modules, providing the capability of isolating one module from theother modules in the system (if there is a fault within that module)while still maintaining the full operation of the system—removing theone problem module from the loop.4. The parallel wiring (bus bar) along with the control system provide away to manage the combining of the power from multiple modules. Thecontrol system allows the power to be distributed and controlled toserve the multiple loads as required. For example, if there are 240 voltloads along with 120 volt loads, the distribution system controls theoutput required to serve these different loads. The combined power ofseveral modules can be leveraged to serve the larger loads, while stillbeing able to maintain the smaller loads via a separate lower voltageoutlet. The control system is an important feature of the connectionsbetween the modules and turns on and off circuits as required.

From a safety and control standpoint, there are also requirements. Eachcircuit must be protected from an electrical fault. This is done withfuses and/or circuit breakers. For control, each subsystem/componentmust have a method of being connected to or disconnected from thesystem. This is done with relays, switches and/or electronic controlsystems (with transistors and the like). This applies locally (to onemodule) and to the whole system (whole assembly). Once the modules arephysically connected (and electrically connected) this isolation andcontrol extends across the whole system/assembly.

Control System:

The control system is comprised of a main controller located in theprimary “P” or main “M” module. Each module that is connected to themain controller also has a controller that connects that module to themain controller, and controls everything within that individual module.The part of the control system that is down at ground level is the userinterface to the control system. It allows the user to monitor andcontrol the system from there, without having to climb up on the roof R(schematically shown in FIG. 2). A similar interface is provided via thewireless connection to the internet. For systems with this wirelessinterface, the user can monitor and control the entire system (andindividual modules connected via the wireless) on their computer via theweb interface.

With a small system (only P modules), the P module's controller is themain controller of the system. Once the P module(s) are connected to anM module, the M module becomes the main controller. All controllers arenetworked to the main controller, and any global monitoring or controlactions are carried out through this main controller.

The control system (CS, or also “controller”) monitors and controls theconnection of additional modules. In order to connect multiple modules,the first or “primary” module (“P” or “PM”) is the first one in thesystem. The primary module can operate by itself with no other modulesconnected to it. In order to increase the total system power, additional“subordinate” or “secondary” modules (“S” or “SM”) can be connected tothe P module. As each S module is connected to the system (placed inline with a number of S modules with P at the head of the system), thecontrol system will confirm that the S modules are compatible and willmake the electrical connections required in order to incorporate theadditional S module into that system. Additional S modules can be placedinto the system until the total rated system power has been reached (or,a “full” system). If an additional module is attempted to be placed intoa full system, the CS will alert the user with audible and/or visualnotifications that the max has been reached. If the user ignores thewarnings, the CS will not allow the module to be electrically connected(even if it is mechanically connected). For every system there is alimit to the number of modules that can be connected to that system. Inthe example shown in FIG. 6b , the maximum number of S modules that canbe connected to the P module are shown. If you attempt to connect anadditional S module to this system (a ninth S module—beyond the 8 Smodules shown), the system will be overloaded. At this point, the onlyway to expand the system beyond 8 S modules is to add an additional Pmodule. The factory preset does not allow the system to operateconnected in this manner (with too many modules for the rating). Thereare user-selected defaults that will allow the mechanical connection,however, the electrical will not be connected (and the warning lightwill remain). The digital readout will indicate what the problems is(ie: too many modules connected to system).

The CS monitors and controls all of the system functions, as aredescribed herein and/or as will be understood by one of skill in the artafter reading and viewing this document and the drawings. The CS isconnected by wiring (data wiring, Ethernet or similar) to the controlunit. While the solar modules are typically placed up on the roof or inan otherwise elevated position, the control system user interface istypically down at ground level so that it is accessible to the user. TheCS can also be connected via wireless (WIFI, Bluetooth, or similar) tothe internet.

In certain embodiments, if there are problems with the system thatcannot be resolved by the user locally, the CS, can be accessed bypersonnel at a remote help desk. In certain embodiments, all of thesystem functions (both monitoring and control) can be done remotelyprovided that there is an internet connection. The local connection tothe internet can also be powered by the SMPS to assure that this featureis always available (even when there is a utility power outage).

Every system issue that arises (faults, under-voltage, over-voltage,over-current, battery failure, etc.) may be reported to the CS and anotification is sent based on the nature of the issue. For seriousissues (fault or complete system failure) there are default settingsthat immediately and automatically take required actions by the CS. Forexample, for a catastrophic event (for example, tree falls on module andcompletely crushes it), the CS will shut down all systems immediately toprevent further electrical damage to the system. All circuits would be“opened” by switches and other means to disconnect and shut down theelectrical system. Other less serious issues may be sent to the CS (forexample, a “trouble”, “notification”, or “alarm” notification, etc) andthe audible and/or visual alarms would sound based on the nature andseverity of the problem.

Energy Management System:

In order to maintain the total storage capacity of the system, the CScontinuously monitors the health of the batteries. The Energy ManagementSystem (EMS) monitors the power production (from solar) and controls howmuch power is delivered to the loads. There are many factors that affectthe storage capacity of the system. How much solar energy is availableon any given day is one of the main factors. If there are multiplecloudy days, the CS will conserve the amount of power that is deliveredto the loads in order to maintain the most important operationalfeatures/apparatus if there is minimized energy production.

Temperature can also influence battery health. The EMS is equipped withtemperature sensors that report the temperature of the electronics andthe batteries. Cooling systems for overheating are preferably includedand can be turned on when temperatures exceed a maximum level (pre-setat the factory based on the battery type). When temperatures drop belowa minimum, actions are taken to keep the battery healthy in theseconditions. Some of these actions preferably include turning off a“fresh air” electronics cooling fan, and turning on a internal“re-circulating” fan that distributes the electronics compartment airinto the battery compartment.

In addition to insulation around the batteries, phase change materialmay also be utilized to even out the temperature swings from day tonight. This prevents both temperature extremes (too hot or too cold). Inaddition to these components, the batteries may be placed on aconductive plate (copper or aluminum or other conducting material) thatis shared with the electronic components compartment. During the summeror hot days, the amount of heat transferred from the electronicscompartment to the battery compartment will be minimal. This is due inpart to the fact that the fresh air fan will be keeping the electronicscompartment cool when it is hot outside. When the air is cold outside,the heat from the electronics compartment will be conducted through thebase plate to the batteries to help them stay warm.

Batteries do produce a small amount of heat when they are charging anddischarging. By connecting several modules together, it is possible touse batteries from one module to charge batteries from another module inthis case. There can also be a small heater in the battery compartmentfor geographic locations that are extremely cold.

Load Shedding:

The way this is controlled is via a load shedding (LS) feature that isselected by the user. There are a minimum of two power outlets (orreceptacles) at the module(s), and preferably at three power outlets (orreceptacles). The priority or each receptacle is indicated to, and knownby, the user in advance, and the user plugs-in/connects the loadsaccordingly depending on the user's perception of theimportance/priority of the loads. For example, if there were threereceptacles and levels of load shedding ranked as A—Highest importanceto C—Lowest priority loads, the user would determine the loadimportance/priority and plug-in/connect them accordingly to thereceptacles. The, in the event of a shortage of solar/battery power, theLS system would “shed” the lowest priority loads first by disconnecting(turning off a switch or relay) the C receptacle. All loads plugged intothis circuit would be turned off if the stored power dropped below apreset level. After turning off load C, the second level would turn offthe B loads before the highest priority loads were at risk of beingturned off.

Under normal conditions, all three circuits would be fully operational.In addition to the circuit management explained above, there are alsolighting circuits that could be dimmed to conserve energy. Any and allof the circuits (A, B and C) can be programmed as dimming circuits, andthe dimming parameters can be pre-set to dim as required when energyneeds to be conserved.

LED indicators at the control unit show the system status. For example,if all circuits are fully charged and operational, the LEDs would show aGreen illuminated LED for circuit A, Yellow for B, and Red for C. In thecase where load shedding is occurring, a flashing LED shows that it isin transition, and once circuit C is turned off, the Red LED would nolonger be illuminated.

Interconnection of Modules:

The interconnection of the modules can be done primarily over the ACsystem or alternatively over the DC power system wiring. The preferredmethod is to have both AC and DC wiring systems shared between themodules.

DC Shared Connections (FIG. 7a ):

This allows for sharing of the stored energy between the modules on theDC system, along with allowing the energy produced from the solar panelsto be allocated across several modules for storage as needed. If onemodule is not collecting enough solar energy to keep its batteriescharged, the other connected modules can charge the batteries of any andall batteries within the connected system. The control system determinesnot only which battery bank(s) within the individual module are to becharged, but also is able to charge battery banks in any of theconnected modules.

From a power delivery standpoint, shared DC power between modules allowsmore energy to be delivered to connected loads, both instantaneous power(in rush current, for example) and total power capabilities areincreased according to the number of modules connected together. Allenergy available can be delivered to any of the connected loads. So ifthere is only one module rated for 500 watts of power and aninstantaneous current maximum of 5 amps, once two of these modules areconnected together, they will have double the capacity (1 kW of powerand 10 amps current).

With shared DC, a larger inverter can be connected to the system at theprimary P or main M module. This, however, is one of the limitations ofa DC only system. Since only the DC system is shared, any larger loadsrequire an inverter sized to handle the largest load. Either everymodule would have its own inverter sized to handle small loads for Stype modules and a larger inverter in the P type module, oralternatively only the main or P module would have an inverter and allloads would be served via this main module. In cases of very largesystems, the main service outlet(s) would require an inverter thatserves both 120 volt and 240 volt loads, and the plug strip wouldrequire larger gauge wire along with receptacles for both 120 v and 240v plugs.

AC Shared Connections (FIG. 7b ):

With shared AC wiring across several modules, each inverter is sized tohandle the power requirements of each individual module. This allowssmaller inverters to be used in each module. Each inverter contributes(in a staged manner as described in the “GRID CONNECTION” section below)to the total power of the system. The power flows from each module tothe P type or M type module at the center of the system. The loads areserved from the P or M module. This allows all inverters to worktogether to deliver the higher power and current required by theselarger loads. The whole system power is the total combined power of allconnected modules. A limitation of having only an AC shared connectionis that it is difficult to share the energy storage of interconnectedmodules. One possible way around this would be to have a battery chargerin each module powered from the AC power. Since the AC power is sharedover all of the modules in the system, the total available power wouldexceed that which is needed for some of the modules and therefore couldafford to deliver more power to the individual modules in need of moreenergy to bring their storage back up to normal levels. This requires anadditional piece of equipment in the form of a battery charging circuitthat adds cost to the system. There are also energy losses in convertingthe DC from the solar to AC via the inverter, and then back to DC againfor the battery charger.

As discussed above, the best features of both systems (sharing both DCand AC power between the modules) drives the design of the preferredsystem. In preferred embodiment, all interconnections between modulesare between BOTH the AC system and the DC system (isolated and separatedfrom each other as shown in FIG. 1, see call-out references DC power 7,AC power 8, and data 9).

Connection of Loads:

The SMPS is equipped with the load shedding capabilities as describedabove. In a small SMPS with one or a few modules, the power isdistributed to the loads via the plug strip as shown in FIG. 1 (seecall-out reference 16). Each receptacle can be turned on or off by thecontrol system to allow lower priority loads to be “shed” when the totalstored energy drops below a pre-set level.

For a larger SMPS, the connection to the loads served is made via anelectrical sub-panel. All circuits that are to be served by the SMPS areconnected to the SMPS sub-panel. In an autonomous system (notgrid-connected) these circuits are isolated from (not connected to inany way) any and all of the normal grid-connected circuits. When bothtypes of circuits are present, the outlets or receptacles connected tothe SMPS are identified (color corresponding to priority levels for loadshedding) so that the user can identify which circuits are available forSMPS loads to be plugged into.

Grid Connected System:

Certain embodiments will be provided with a grid-tie, that is, connectedto the utility power grid for cooperation with said grid, during atleast some periods of time.

On a normal or traditional solar power system with micro inverters, allof the micro inverters are “on” (and turned on and off) at the same timebecause they are “pushing against” a much higher power system (utilitypower) that can handle the total produced solar power.

Conversely, with the SMPS, only the grid connected module (either P or Mdepending on the system) is matching the AC waveform of the utility(FIG. 8b ). This is used as a reference for the subordinate panels tomatch to. In addition, the connection of subordinate inverters is stagedto allow each module to sync to the main inverter individually, andtherefore not placing too much load on the system simultaneously. Thisallows the control system to confirm that the main or primary invertercan handle each subordinate module in turn, and make adjustments asnecessary. The inverter in every module can be turned on and/or isolatedfrom the system as necessary to keep the entire system operatingproperly. In this way, faults can be isolated and still allow the restof the system to be fully operational.

This configuration allows the turning on and off of the inverters in anorderly and staged manner when matching the utility AC, both when thegrid turns on and when the grid shuts off.

The only inverter that syncs to or matches the utility AC waveform isthe main or primary module that is actually physically connected to theutility grid (via a plug in connection or hard wired). This invertermatches the utility's waveform in the same way that a normal grid-tiedinverter does. What is different in the SMPS is how the other invertersin the system operate once the main utility connection has been made (orhas been disconnected). Each of the subordinate inverters match the MAINmodule AC waveform (not the utility). This allows the MAIN module tocontrol the subordinate modules with or without a grid connection.

When the AC signal is lost from the utility (a utility grid poweroutage), the MAIN module disconnects from the grid via AutomaticTransfer Switch (FIG. 8b , note 104) and immediately starts generatingit's own AC signal for the subordinate panels to sync to. In this way,the subordinate modules will continue to operate, sourcing their powerfrom the batteries rather than the utility. If the pool of stored energyin the batteries (or other storage device) is not large enough to carrythe entire load when the utility connection is lost (during the utilitypower outage), the control system will shed loads as required to allowthe system to carry only the loads on the prioritized circuits asidentified.

With a grid connected system as described, the excess power generated bythe solar can be pushed out onto the grid once the batteries are fullycharged.

Small System Grid-Tied Interface:

Load shedding when small (4 box SMPS) system is tied to an existinggrid-tied electrical-circuit:

The connection to the grid by the preferred SMPS is preferablyadapted/configured so that when the utility power is off-line, the SMPSis still 100% operational (see discussion above). Since the SMPS is muchsmaller (1 kW for SMPS connected to a grid-tied 5 kW system), the 5 kWhof storage capacity may only support a small portion of the connectedloads of the entire system. The load shedding will determine which loadscan be served overnight. It will warn (visual and audible notifications)that another circuit is going to be turned off prior to doing so. In themorning when the sun comes up there will be more than enough power tosupport all of the circuits, and the SMPS will notify prior to turningon each circuit.

Connection Methods for a Small System (FIG. 8a ):

For a small (1-4 module) SMPS, the system is plugged into agrid-connected receptacle. This connects the SMPS to that circuit (lessthan 15 amps, controlled at the service panel by a breaker, andprotected for overload by that breaker or fuse).

A medium size system (5-9 modules) can be connected to the system via anexisting large receptacle or outlet. Typically, a household clothesdryer outlet is a higher amperage and voltage. The SMPS would be pluggedin to the dryer outlet and an additional outlet would be provided atthis interface for the dryer to be plugged into. This provides theinterface for the SMPS to connect to the grid (via the dryer receptaclecircuit). This dryer receptacle circuit would need to be rated highenough to handle the SMPS. However, most of the SMPS are smaller thanthe typical dryer circuit. Most dryer circuits are rated at 30 amps and240 volts which can handle up to 6000 watts (6 kW). A SMPS with 20modules is capable of about 6 kW (a very large system). If a systemlarger than 20 modules is to be connected to the same electricalservice, then the second part of the system would have to be plugged into a second receptacle. For example, an existing electric stove and/orelectric cooking range could be rated up to 50 amps at 240 volts. Inthis case (with two SMPS systems plugged into two separate outlets), thefirst system would need to be the controlling or “main” system, and thesecondary SMPS would be subordinate to the main.

All loads served by the small SMPS are plugged into the power strip thatallows each circuit to be managed by the control system. Load sheddingis done by switching on or off each receptacle in the plug strip. Eachreceptacle in the plug strip has an indicator light next to it showingwhether or not that individual receptacle or circuit is active or not.The color of each indicator light identifies which circuit and whichpriority each receptacle serves. Lower priority circuits are shed first,keeping the higher circuits active.

Large System Grid-Tied Interface (FIG. 8b )

Load shedding when a large SMPS is tied to an existing grid-tied systemworks the same as it does for a small system, alerting the user prior toany loads being shed.

The connection to the main service panel can be done in one of threeways:

1. Main module is connected via dryer or 240-volt receptacle asdescribed for a small SMPS. In this case all of the loads are pluggedinto the plug strip for control of the load shedding.

2. A sub-panel with Automatic Transfer Switch (ATS) is connected aheadof the main service panel. This allows priority loads to be served bythis new subpanel. Less important loads remain served by the existingmain service panel. All circuits that are deemed high enough priority tobe served when the utility power is out are re-routed to this new SMPSsub-panel. The load shedding is done for each of these circuits, andonly these circuits will be served when the utility power is out.

3. The main service panel is replaced with a SMPS service panel (withATS). All of the existing (or new for new construction) circuits areserved by the SMPS service panel. All circuits are controlled by thecontrol system and can be shed if required when there is a utility poweroutage.

When equipped with either a sub-panel (with ATS) or a main SMPS panelwith ATS, the system can allow the operation of additional grid poweredsolar panels (on the same system) to be operational during a poweroutage. When the grid power goes out, the ATS transfers power to theSMPS which in turn generates an AC signal. This AC signal provides areference for the grid-tied inverters to sync to. During a power outage,not only the SMPS is operational but all of the grid-tied inverters onthe same system would also be operational. This allows more power to beavailable during the day. Both Grid-tied solar panels and SMPS solar areavailable during the day, then the energy storage system carries some ofthe loads (prioritized according to the load shedding) at night.

It may be noted that the term “modular” means that a system isexpandable in order to increase the total system power by addingmodules, for example, meaning that each module is compatible with theother modules in the system and can be connected (both electrically andmechanically) together. Modules are interchangeable and compatible witheach other without any modification, except that, preferably, there are“right” and “left” modules, however, to connect in a manner as shown anddescribed for FIG. 4b and its air flow channels.

Referring Specifically to the Figures:

A single module 100 is shown in FIG. 1, which is fully functionalwithout any other modules connected to it, thus, it is self-contained.The top surface of the module is a solar collector 1 that covers theentire, or substantially the entire, top surface. The enclosure 3 or“housing” is weatherproof and houses all of the electronics and wiring.In order to allow for the expansion of the system by interconnection ofmultiple of the modules, the module 100 has a mechanical track 5 thatallows a second module to be slid into the track and connected to thefirst module 100. Openings for air flow 6 on the side (preferably a sideedge) of module 100 are described in more detail below, regarding FIG. 3and FIG. 4. There are three electrical connector sections in the track 5(or “track assembly”) providing connection points for each of theelectrical systems. The first track section is for DC power 7, thesecond section is for AC power 8, and the third is for data/control 9.Each of these track sections have a conductive section/electricalfitting 12 that physically mates to the adjacent module connecting thecircuiting between the two modules. See FIG. 3a . The external powerreceptacle 14 is on the bottom face of the corner wing, as shown inFIG. 1. This allows the outlet and plug to be protected from theweather. The extension cable 15 consisting of power and data wiring isplugged in to the receptacle and extended to the electrical loads to beserved by the system. Plug strip 16 with receptacle 17 and indicatorlight 18 identifies which priority each receptacle is for load shedding.While one receptacle 17 and one indicator light 18 are called-out inFIG. 1, one may see three pairs of receptacle 17 and light 18 along thelength of the strip 16. Digital display 19 readout shows systeminformation. USB outlet and RJ45 port 20 for connection of data controlcable.

FIG. 2 illustrates an example of a system 200 with four modules,including one “primary” module 21 connected to three other “secondary”modules 22. Each module has conductive bussing running the length ofeach interior side of the module 24, and along the interior top andbottom walls 26. Section “A” shown in FIG. 2 is detailed in FIGS. 3a andb.

The cross-section of the interface (here, “interconnection” includingmechanical and electrical connection) between two adjacent modules isshown in FIG. 3a . The mechanical track 30 of FIG. 3a is configured toprovide a mating channel to slide the two modules together. As themodules are slid together along the channel track, and as the connectionpoints 12 for the primary module, and connection 13 for the secondarymodule come into alignment, they will contact each other and make theelectrical connection once the track travel has fully seated and come toa stop. The bus bar 36 in the primary module is connected to the bus bar38 in the secondary module via this connection. The top section of thechannel has an airway trough 32 to provide an airway for venting of theinterior of the modules. Each module has a hole or opening 6 on thesidewall of the enclosure to allow hot air to exit the enclosure andventilate the air thru the channel and out the top of the channel.Passive heat transfer from the interior of the module to the outside airwill occur as the heated air is drawn upward to the top of the channeland vented out. The bus bar 36 in the primary module is connected to thebus bar 38 in the secondary module via this connection. Weather-strip 40protects the channel from water entry. Whatever little water or moisturethat may enter the channel will flow down the bottom of the airwaytrough 32, and drain out the bottom. Screen 43, against/over opening(s)6, protects the entrance of the module from insects and debris, and onlyallows air to flow thru the opening.

As shown in FIG. 3b , a channel cover 39 is slid onto module sides(“side edges”) that are not adjacent to another module, for example, foran “outer” module such as shown at view line 3 b-3 b in FIG. 4B. Thisprovides a channel for the air flow, and protects the channel, includingit electrical elements, from the weather. The channel cover runs thelength of the channel along the side of the module.

FIG. 4a is a schematic view of a module, with its top solar panelremoved, and illustrating only the inverter 42 and fan(s) 44 inside theinterior space I of the module enclosure. Openings 33 and opening 34(see also openings 6 in FIGS. 1, 3 a and 3 b) are at opposite ends ofthe module. In many embodiments, the orientation of the module on aslanted roof/surface will place the openings 33 (and the respective “topend” of the module) higher in elevation relative to openings 34 (and therespective “bottom end” of the module). Given such an orientation, FIG.4a demonstrates an example of how the airflow travels thru a singlemodule to ventilate heat from the interior I of the enclosure to theoutside. Hot air inside the module rises to the top of the enclosure andis drawn to the outside thru the upper opening(s) 33 at the top end ofthe module. Cooler air from the outside is drawn in from the bottom ofthe enclosure thru the lower opening(s) 34 at the bottom end of themodule. Heat from the solar panel at the top side of the enclosure,along with additional heat from the inverter 42 and other electroniccomponents (not shown in FIG. 4a ) will contribute to this process. Inaddition to the natural convection of heat, and/or if the orientation ofthe module is less slanted, fan(s) 44 increase the air flow and assistin the heat transfer thru the enclosure.

FIG. 4b illustrates how the airflow channels/passages may be establishedfor air travel in a network/assembly of modules. Some of the modules(ML) have their fresh air openings on lower, left side edges, and otherof the modules (MR) have their fresh air openings on lower, right sideedges, with the hot air openings at the opposite side edges of eachmodule. Therefore, a column of ML modules will be connected to anadjacent column of MR modules, next to another column of adjacent MLmodules; this forms, from left to right in FIG. 4b , a fresh air channelQ at the far left, a hot air channel R, another fresh air channel S, andanother hot air channel T. In other words, fresh air channels (Q and S)alternate with hot air channels (R and T). Thus, fresh air enters intothe lower ends/corners of the modules at channels “Q” and “S” (at theside edges of the modules were are located the fresh-air openings). Seefresh air arrows FA1 to the lower three modules, and also fresh airarrows FA2 to the upper three modules. Thus, the hot air tends to leavethe modules (see arrows HA1 for the lower modules, and arrows HA2 forthe upper modules) from the upper openings, flowing into channels “R”and “T” and then out of those channels on the upper end of the moduleassembly. The hot air is drawn generally from the lower/bottom end ofthe assembly, to the upper/top end of the assembly, and, hence, to thetop outside air. Specifically, the hot air exiting from each moduleflows into the channel along the end-to-end length of each of themodules, and flows through the channel toward the top end of theassembly of modules, to exit to the ambient air. This way, each channelmaximizes the efficiency of the heat transfer, since hot air from onemodule will not enter another module on its way to the outside. The airentry point 34 of each module is at/near one end and one side edge ofthe module, and the air exit point 33 is at/near the opposite end andopposite side edge of the module, allowing the airflow to go across theentire surface area and volume that needs to be ventilated (along theentire or substantially the entire length L between said opposite ends,and across the entire or substantially the entire width W between theopposite side edges). Refer to FIG. 4a . In certain embodiments, thisair does not flow through the battery chamber, but instead bypasses oris otherwise blocked from doing so. Channel cover 39 provides such apassage for the air flow on channel side edges not adjacent to anothermodule; refer to FIG. 3b . It may be noted that the left and right sideedges of the modules in a given row of the assembly in FIG. 4b areconnected mechanically and electrically by the channels/tracks, asdescribed herein, while the rows of modules may be connected togethermechanically, by various fasteners for example, at their top and bottomside edges, if desired.

The interior of the module, with all of the preferred componentscontained therein, is shown in FIG. 5a . The inverter 42 is adjacent tothe batteries 52 and is separated by insulation. All of the electricalcomponents are in a separate compartment from the batteries. Thisprovides a thermal barrier to protect the batteries from the heat of theelectronic components and the solar panel. Examples of the preferredMaximum Power Point Tracker (MPPT) 54, Charge Controller (CC) 56,Control System (CS) 58, Electronics compartment temperature sensor (T)60, Battery compartment temperature sensor 61, AC circuit protection andcontrol 64, DC circuit protection and control 65, Battery compartment67, and Electronics Compartment 68, are illustrated, and it will beunderstood from this document and the drawings, combined with theaverage skill in the art, how these elements will be connected andoperated.

FIG. 5b is a cross section of the enclosure illustrating the heattransfer and insulating features of the system. The inverter 42 issitting on and thermally connected to the conductive plate 51 thatprovides pathway for heat transfer to the batteries 52. The batteriesare insulated on all sides 50. There is a dead air space 53 above theentire solar panel 1 that provides a passageway for the airflow from theintake and exit holes in the sidewalls of the enclosure. This airspacekeeps the back side of the solar panel cool, and prevents excess heatfrom entering the enclosure.

The simplest system consists of just one module; said just one modulemust be a “P” type, or “primary module” (PM) so that it can communicateto the CS and provide all of the required functions. More complicatedsystems may comprise, consist essentially of, or consist of multiplemodules connected mechanically and electronically into moduleassemblies. FIGS. 6a-c Illustrate the various types of modules and some,but not all, examples of how multiple modules may be connected together.The additional modules, over and above said just one module, can beconnected to the P as secondary or subordinate “S” type modules (orsubordinate modules (SM)). The S modules rely on the P for control andinterface to the CS. For the case where a system is larger (more power)than that which a P plus S system can handle, then an additional “M” or“main module” (MM) can be added to connect multiple P modules. In thiscase, the entire system control is thru the M, with all of the P modulesbeing subordinate to the M.

The row of modules in FIG. 6a shows the ratings of each of the preferredmodule types. The S module 70 has a local rating (for the individualmodule) of 500 watts, and a system rating of 2.5 kW. The system ratingindicates that S can be placed within a network of modules up to 2.5 kW.The P module 72 has a local rating of 2.5 kW (for the local network withits subordinate S type modules), and a system rating of 5 kW. The Mmodule 74 has a system rating of 20 kW.

The row of modules in FIG. 6b illustrates an example of a P moduleconnected to four S modules on each side of the P module. A first set 76of modules, therefore, may be said to be the four S modules on the left,plus the primary module P. A second set 78 of modules may be said to bethe four S modules on the right that connect to P parallel to the Smodules of the first set 76. Since each S module can have up to 500watts of production and consumption, the combined total power of allfive modules (the P module plus four modules on one side of the Pmodule) is 2500 watts, consistent with the local rating of 2.5 kW of P.Note that there are four additional S modules, each rated for 500 watts(0.5 kW), on the other side of the P module, for a total of eight Smodules, which is 4 kW total. The P module only adds 500 additionalwatts to the total, for a total 4.5 Kw, with 5 kW being the total systemrating (see the 5 kW system rating for P).

In FIG. 6b , it may be noted that the 2.5 kW is the “local” rating of P(only for the individual module itself), so if there were a P modulewith no other connected panels it could handle up to 2.5 kW in localloads (loads that are plugged directly in to the P module). The Smodules can handle up to 500 watts in local loads, and up to 2.5 kWshared loads (if in a system as shown). Therefore, S modules are shownin FIG. 6b on either side of the P module, with 4 on each side. If 8modules were on one side of the P module, the total connected load wouldexceed the 2.5 kW rating. Since there are only 4 S modules in series(four on either side of the P), any one of the individual S modules willnever experience more than it's rating of 2.5 kW.

The rows of modules in FIG. 6c indicate how each of the P modules servefour S modules, and in turn feed into the M module. Each M module serves3 P modules at 2.5 kW each for a total of 7.5 kW. Since the M module israted for 20 kW, this configuration is well within the ratings of thisexample.

FIG. 7a illustrates the connection of modules via DC power 80, sharingthe power by connecting all of the batteries 52 of the 3 modules (S, P,and M modules) in parallel. The inverter 42 of each module draws fromthis pooled or shared energy storage system as needed to serve theirindividual loads. Note the 120 VAC from modules S and P, and the 240 VACfrom module M.

FIG. 7b illustrates an AC shared connection, where the AC wiring 82 isshared, and all of the inverters operate in parallel. In thisconfiguration, the subordinate inverters sync to the primary inverter inmodule P, as discussed earlier in this document. FIG. 8a illustrates howa small SMPS is connected to the grid. Extension cable 15 extends powerfrom the primary module 21 to the plug strip 16 which feeds aplug/receptacle 87 via extension cable 86. The plug 87 plugs into thewall receptacle 90 which is connected to grid power via the electricalservice panel. Plug 87 also has a receptacle on the back side whichallows the dryer or other electrical appliance plug 92 to be pluggedinto the receptacle 87.

FIG. 8b shows how the SMPS is connected to a sub panel for powerdistribution. The primary module 21 provides power via power cable 96 tosub-panel 95. This sub-panel is connected to the utility power viaconnecting service line 97 to the line or bussing 99 ahead of the mainservice panel 102 and after the meter 98. The Automatic Transfer Switch104 senses when there is a utility power outage and isolates the SMPSfrom the utility power. Line 106 indicates loads served by the SMPS.Loads served by sub-panel 95 are served by the SMPS when the grid isdown.

FIG. 9 is a wiring diagram of an individual module. The solar panel 1 isconnected to the maximum power point tracking (MPPT) device 54 which isconnected to either the charge controller 56 when charging thebatteries, or to the inverter 42 when the inverter is called to servedirectly from the solar power to the connected AC loads by the controlsystem. Relay 110 allows the control system to make this switch. Thecharge controller 56 charges the batteries 52, and each of the batterybanks can be isolated from the DC power bus by relays 112. The controlsystem 58 controls all of the system devices as shown including the MPPT54, inverter 42, charge controller 56, electronics temperature sensor60, battery temperature sensor 61, fan 62, and heater 63. The batteriesdeliver power to the DC power bus 116 that provides power to all localdevices, and is also connected to adjacent modules as described in FIG.1 and FIG. 2. The inverter 42 delivers AC power to the AC power bus 114which also connects to adjacent modules as required. Wireless device 109connects to the control system to allow remote wireless monitoring andcontrol of the system. Relays 108 and 110 allow the inverter to beisolated from the system.

Certain embodiments of the invention may be described as a solar modularpower system, preferably for installation on a roof or other elevatedlocation that receives solar insolation. The preferred system comprisesmultiple modules each having photovoltaic cells/panel(s), wherein acertain type of module (a primary module) is designed so that it canoperate on its own, as a single, self-contained solar module providingAC or DC and preferably both, to one or more loads. The primary module,in addition to a solar panel(s) and elements to produce AC, DC, andpreferably both AC and DC power, also comprises control and/ormonitoring and/or communication/wireless apparatus for the entireassembly (the entire “system”). Additional, subordinate module(s) mayalso be provided for mechanical and electrical attachment to the primarymodule, to increase AC, DC, or preferably both AC and DC powerproduction. Therefore, preferably each module (both primary andsubordinate) is designed to connect to and work with other modules, forhigher power output, by means of each module being adapted to work atthe full power rating of the entire assembly (entire system). Therefore,up to a predetermined number of subordinate modules may be connectedelectrically in series to the primary module, and preferably alsomechanically connected, to be secured into single structural unit.Further, in certain embodiments, multiple of theprimary-module-plus-subordinate-module assemblies (P plus S assemblies)may be connected in parallel to a main module, that may compriseadditional of said control and/or monitoring and/orcommunication/wireless apparatus for the entire assembly (entire systemof two or more P plus S assemblies connected to M).

In the assemblies/systems of the above paragraph, each module preferablycomprises a module housing that holds the solar panel(s) on one or moreof its surfaces (preferably on a top, broad and flat surface), whereinthe solar panel(s) may be of any type such as a flexible solar panel orrigid solar panels or cells, and of any composition currently known ordeveloped in the future. The module housing contains in its interiorspace the other elements needed for the module operation, control, andprotection, wherein the housing is further adapted to include ports forrequired operative connections (via the “outlets” or other electricalconnection sites) to other modules and/or to loads. The modules,therefore, may be described in many embodiments as separate boxes, allof the same or approximately the same dimensions, that can be stacked ina courier-approved-size package, and shipped to a user. Then, themodules may easily be placed on a roof or other support and connectedtogether and made operative without significant knowledge except to readinstructions included with the package. Preferably, the connection is aconvenient slide-together or snap-together connection that serves bothmechanical and electrical connection, but, alternatively, the modulesmay be mechanically connected together by fasteners, clips, plates,racks, or other connectors, and plug-in wiring may be used to make theelectrical connections.

The elements in and on each module for operation of each module of theabove two paragraphs may comprise, consist essentially of, or consistof, elements to generate and store solar energy, and to provide DC, orAC, and preferably both DC and AC power, to a load(s) that is/areoutside the module but electrically connected (typically plugged into areceptacle) to a power outlet of the module or to a power outlet of thesystem/assembly of modules. Said elements in each module may include thesolar cells/panel(s) (such as photovoltaic cells/panel(s)), one or morebatteries or other energy storage devices, a Maximum Power Point Tracker(MPPT) such as one available commercially and understood in the art, acharge controller (CC), a control system (CS), relays to isolate thebattery/storage-device from the DC power bus, an inverter delivering ACpower to an AC power bus (which can also be connected to adjacentmodules as required to increase the total AC power output of thecombined system) to directly provide energy from the solar power to theconnected AC load(s) via the control system (and a relay to allow thecontrol system to make this switch), an electronics compartmenttemperature sensor, a battery/energy-storage compartment temperaturesensor, fan and/or heater, AC circuit protection and control, DC circuitprotection and control, and a wireless device connected to the controlsystem to allow remote wireless monitoring and control of the system.Certain embodiments may comprise, consist essentially of, or consist of,the elements schematically portrayed in FIG. 9. These elements willtypically be separated to be contained within a battery compartment, andan electronics compartment, inside the housing of the module.

These elements, of the previous three paragraphs, are provided andoperationally connected, when multiple of the modules are connected intothe multiple-module system, so that each individual module is able tocollect (via the solar panel), store (in batteries or other energystorage system) and deliver to external loads the energy collected bythe solar panel, with the capacity to handle a total higher load thanjust one module. Said elements of the module and their particularoperational connection are important because each module of the systemmust be: 1) compatible with the other modules (mechanically andelectrically), and 2) have a power rating high enough to handle all ofthe power over the entire system, and 3) have a control system to managethe power (since it is shared over the entire system). Regarding theitem no. 1 compatible electrical operational connections, it isnecessary to electrically connect both the AC wiring of each module tothe AC wiring of the other modules in a given series of modules, and theDC wiring of each module to the DC wiring of the other modules in agiven series of modules, and to keep the AC wiring and the DC wiringisolated from each other (as described in detail in this document andthe figures). Regarding the item no. 2 power rating for each modulebeing high enough to handle all of the power over the entire system,this is important because: a) one cannot combine multiple systems ormodules unless the total system is capable of supporting the combinedloads, b) the combined loads vary depending on how many modules areconnected together, and c) the modules and their operational connectionmust be designed to accommodate this variance. Regarding the item no. 3control of operational connection, the system comprises a control systemand (preferably wireless) communication to a control station/unit, tomanage operations of each module (“in-box” or “within a given module”)and also of the system as a whole (that is, control of functions “out ofthe box”, that is, “between modules of the system” and “between thesystem and the loads”), for example, energy storage in thebatteries/energy-storage and load shedding. Load shedding on the loadside of the system allows energy management that conserves power whenthe energy storage system (batteries or the like) is low. Further, thepreferred control of the system as a whole further comprisescontrol/adaptations to match the utility grid AC waveform, specificallyin certain embodiments, the system comprises the ability to matchutility AC power waveform with the main inverter, and then to syncadditional inverters (of subordinate modules, for example) to the maininverter (of the primary module, for example).

Certain embodiments as described in the four paragraphs immediatelyabove, may comprise grid-connection with ability to serve connectedloads with grid-power. This allows “back-up” power if the batteries everget too low (alternative to load shedding). This may also allow aback-up in the case of any other failures within the module that mayprevent its operation (for example, inverter failure).

Certain embodiments, such as those described in the five paragraphsimmediately above, may include one or more of the following features:

a) a mechanical channel or track to mechanically and electricallyconnect modules;

b) air flow to allow cooling of interior of module enclosure(s), whichair flow may in certain embodiments be through said mechanical channelor track;

c) passive heat transfer from inverter to batteries for cold weather;

d) optional heating unit for heating batteries in extreme cold climates;

e) insulated batteries;

f) phase change material to even out the temperature swings;

g) light weight energy storage system such as LiFE PO4 batteries orultra-capacitors;

h) control system (CS) including energy management system

i) MPPT shared by both inverter and charge controller (which savesmanufacturing costs); and/or

j) optional cooling fan controlled by CS.

Certain embodiments, such as those described in the six paragraphsimmediately above, may include one or more of the following features:

a) the total system is preferably organized with a hierarchy of a“primary” module that serves multiple subordinate or “secondary”modules;

b) primary modules may be connected to one “main” module that servesmultiple primary modules with their attached subordinate modules;

c) the control system controls not only the local module specificfunctions, but also controls and manages the power between modules andover the entire system, and, hence, also the power available from theentire system;

d) the CS isolates faults from the system, for example, disconnectingindividual battery banks, disconnecting faulty solar panels,disconnecting and isolating faulty inverters; and/or

e) the CS interconnects all of the systems of the combined modules thatallows the entire system to operate as a whole, for example, wherein theenergy generation systems (solar) can charge any and all of the energystorage systems within the entire system, so that the combined energystorage can serve any and all connected loads.

Certain embodiments, such as those described in the seven paragraphsimmediately above, may include one or more of the following features:

a) automatic transfer switch to allow isolation or “islanding” of thesystem when there is a power outage, which makes it possible for thesystem to be fully operational when the grid is down; and

b) providing AC signal to the local system, isolated by the ATS duringpower outage for reference to other solar grid-tied inverters allowingtheir operation during a power outage.

Certain embodiments may be described as: A solar powered modular systemcomprising:

a plurality of modules, each comprising a housing, a solar panel on atleast one outer surface of the housing that is adapted to produce powerfrom solar insolation, a DC system comprising an energy-storage device,a charge controller that controls charging of the energy-storage devicefrom energy produced by the solar panel, DC wiring and a DC outlet, andan AC system comprising an inverter connected to at least one of thesolar panel and the energy storage device, AC wiring, and an AC outlet;each of the plurality of modules being electrically connected inparallel to form a module assembly for connection to power one or moreelectrical loads; wherein the DC systems of the modules are electricallyconnected in parallel, and the AC systems of the modules areelectrically connected in parallel; and wherein each of the modules hasa full power rating equal to or greater than a sum of maximum powerproduction of each of the electrically-connected modules, so that themodule assembly is adapted to be connected to, and to power, said one ormore electrical loads that total to be a higher total load than each ofsaid modules is adapted to power individually. Therefore, in certainembodiments there may be subordinate modules operatively (electrically)connected in parallel to a primary module that comprises controlcapability, wherein all the modules of such an assembly are preferablyin parallel; and, in certain embodiments, multiple of such primarymodules (with the connected subordinate modules) may be connected inparallel to a main module that has further control capability, whereinall the modules of such an assembly are in parallel.

Certain embodiments may be described as:

A solar-powered modular system comprising:

a first set of modules, each comprising a housing, a solar panel on atleast one outer surface of the housing that is adapted to produce powerfrom solar insolation, a DC system comprising a charge controller thatcontrols the power flow of the DC system, DC wiring and a DC outlet, andan AC system comprising an inverter connected to at least one of thesolar panel and the energy storage device, AC wiring, and an AC outlet;each of the plurality of modules being electrically connected inparallel to form a module assembly for connection to power one or moreelectrical loads; wherein the DC systems of the modules are electricallyconnected in parallel, and the AC systems of the modules areelectrically connected in parallel; and wherein said first set ofmodules comprises one primary module and subordinate modules, whereinthe primary module further comprises a control system adapted to monitorand control the DC power system of each of the subordinate modules andthe inverter of each of the subordinate modules to maintain an ACwaveform generally matching a utility power grid AC waveform; and thesolar-powered modular system further comprising a second set of modulescomprising subordinate modules that are connected in parallel to saidprimary module of said first set in parallel to the subordinate modulesof said first set, wherein said control system of the primary module isadapted to monitor and control the DC power system of each of thesubordinate modules of said second set and the inverter of each of thesubordinate modules of said second set to maintain an AC waveformgenerally matching a utility power grid AC waveform; and wherein each ofthe subordinate modules of said first set has a full power rating equalto or greater than a sum of maximum power production of each of thefirst set subordinate modules and the primary module, wherein each ofthe subordinate modules of said second set has a full power rating equalto or greater than a sum of maximum power production of each of thesecond set subordinate modules and the primary module, and the primaryhas a full power rating equal to or greater than a sum of all of themodules of said first set and said second set, so that the primarymodule is adapted to be connected to, and to power, said one or moreelectrical loads that total to be a higher total load than each of saidmodules of the first set and the second set is adapted to powerindividually.

Although this invention has been described above with reference toparticular means, materials and embodiments, it is to be understood thatthe invention is not limited to these disclosed particulars but extendsinstead to all equivalents within the scope of the following claims.

The invention claimed is:
 1. A solar-powered modular system comprising:a plurality of modules, each comprising a housing, a solar panel on atleast one outer surface of the housing that is adapted to produce powerfrom solar insolation, a DC system comprising a charge controller thatcontrols the power flow of the DC system from energy produced by thesolar panel, DC wiring and a DC outlet, and an AC system comprising aninverter connected to at least one of the solar panel and the DC system,AC wiring, and an AC outlet; each of the plurality of modules beingelectrically connected in parallel to form a module assembly forconnection to power one or more electrical loads; wherein the DC systemsof the modules are electrically connected in parallel, and the ACsystems of the modules are electrically connected in parallel; andwherein each of the modules has a full power rating equal to or greaterthan a sum of maximum power production of each of theelectrically-connected modules, so that the module assembly is adaptedto be connected to, and to power, said one or more electrical loads thattotal to be a higher total load than each of said modules is adapted topower individually.
 2. The solar-powered modular system of claim 1,comprises a connection to a utility electrical power grid characterizedby an AC waveform, wherein one of said modules is a primary module andothers of the modules are subordinate modules, wherein the primarymodule comprises an inverter that synchronizes AC power that is outputfrom the primary module to have a primary module AC waveform thatmatches said AC waveform of the grid, and wherein the solar-poweredmodular system comprises a control system that causes the inverters ofthe subordinate modules to synchronize to the primary module AC waveformso that all the inverters of the module system are synchronized to theutility power grid when the assembly is connected to said grid.
 3. Thesolar-powered modular system of claim 2, wherein, during a utilityelectrical grid outage or disconnection, said control system maintainsthe inverter of the primary module and the inverters of the subordinatemodules producing AC power in said primary AC waveform, without the gridconnection.
 4. The solar-powered modular system of claim 1 thatcomprises multiple power outlets to power multiple of said electricalloads, wherein the power outlets are each assigned a level of importancefrom low importance to high importance, and the system comprises acontrol system that, if DC power level in the module assembly is low,turns off one of the multiple power outlets at a time from lowimportance to high importance.
 5. The solar-powered modular system ofclaim 4, wherein the multiple of said electrical loads are detachablyplugged-in to the multiple power outlets so a user selects what load isplugged-in to each power outlet according to a determination by the userof the importance of each load.
 6. The solar-powered modular system ofclaim 1, comprising a connection to a utility electrical power grid, anda control system that draws power from the power grid to charge at leastone or more energy-storage devices of the multiple modules, when storedenergy in the energy-storage devices drop below a predeterminedthreshold level.
 7. The solar-powered modular system of claim 1, whereinthe multiple modules are mechanically connected into a single unit. 8.The solar-powered modular system of claim 7, wherein the multiplemodules are mechanically connected by each of the modules comprising achannel/track, wherein the channel/track of each module slidably mateswith the cooperating channel/track of an adjacent module to secure themodules together.
 9. The solar-powered modular system of claim 8,wherein said channel/track of each module slidably mating with thecooperating channel/track of an adjacent module also electricallyconnects the modules.
 10. The solar-powered modular system of claim 8,wherein each of the modules comprises multiple of said channels/tracksprovided on multiple side edges of each module, for mechanicalconnection on at least two side edges to adjacent modules.
 11. Thesolar-powered modular system of claim 1, wherein the housing comprisesapertures for air flow for cooling of an interior space inside the eachmodule.
 12. The solar-powered modular system of claim 1, comprising aheat-conductive plate adapted for heat transfer from the inverter to thehousing interior for cold weather.
 13. The solar-powered modular systemof claim 1, comprising a heating unit inside the housing for heating inextreme-cold climates.
 14. The solar-powered modular system of claim 1,comprising insulation inside the housing and surrounding electronicswithin the enclosure.
 15. The solar-powered modular system of claim 1,comprising a cooling fan controlled to turn on in response to atemperature sensor.
 16. The solar-powered modular system of claim 1,comprising phase change material inside the housing to even out thetemperature swings inside the housing.
 17. The solar-powered modularsystem of claim 1, wherein said MPPT is shared by both the inverter andthe charge controller.
 18. The solar-powered modular system of claim 6,wherein said solar panel of each module charges the energy-storagedevices of all of the modules.
 19. The solar-powered modular system ofclaim 6, wherein said energy-storage device of each module providesenergy to multiple loads, including loads connected to any of themodules.
 20. A solar-powered modular system comprising: a first set ofmodules, each comprising a housing, a solar panel on at least one outersurface of the housing that is adapted to produce power from solarinsolation, a DC system comprising a charge controller that controls thepower flow of the DC system from energy produced by the solar panel, DCwiring and a DC outlet, and an AC system comprising an inverterconnected to at least one of the solar panel and the DC system, ACwiring, and an AC outlet; each of the plurality of modules beingelectrically connected in series to form a module assembly forconnection to power one or more electrical loads; wherein the DC systemsof the modules are electrically connected in series, and the AC systemsof the modules are electrically connected in series; and wherein saidfirst set of modules comprises one primary module and subordinatemodules, wherein the primary module further comprises a control systemadapted to monitor and control the DC systems of each of the subordinatemodules and the inverter of each of the subordinate modules to maintainan AC waveform generally matching a utility power grid AC waveform; andthe solar-powered modular system further comprising a second set ofmodules comprising subordinate modules that are connected in series tosaid primary module of said first set in parallel to the subordinatemodules of said first set, wherein said control system of the primarymodule is adapted to monitor and control the DC systems of each of thesubordinate modules of said second set and the inverter of each of thesubordinate modules of said second set to maintain an AC waveformgenerally matching a utility power grid AC waveform; and wherein each ofthe subordinate modules of said first set has a full power rating equalto or greater than a sum of maximum power production of each of thefirst set subordinate modules and the primary module, wherein each ofthe subordinate modules of said second set has a full power rating equalto or greater than a sum of maximum power production of each of thesecond set subordinate modules and the primary module, and the primaryhas a full power rating equal to or greater than a sum of all of themodules of said first set and said second set, so that the primarymodule is adapted to be connected to, and to power, said one or moreelectrical loads that total to be a higher total load than each of saidmodules of the first set and the second set is adapted to powerindividually.